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Operation and Installation Manual
Atlas | Operation and Installation Manual
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Atlas | Operation and Installation Manual
Last Revision Date: December 18, 2018
For the most up-to-date information for this product and others, please contact
Simplex, Inc. at (800) 637-8603 or visit us on the web at
http://www.simplexdirect.com.
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Atlas | Operation and Installation Manual
- Table of Contents
I. Warnings and Cautions ............................................................ 4
I-A. Safety Information Symbols ....................................................4
I-B. Warnings ..................................................................................4
II. Description and Specification ................................................. 7
II-A. Specifications ..........................................................................7
III. Unpacking .............................................................................. 8
III-A. Included Components and Parts ...........................................8
III-B. Primary Inspection .................................................................8
IV. Installation ............................................................................. 9
IV-A. Load Bank Placement ............................................................9
IV-B. Wiring the Load Bank ............................................................9
V. Operating Instructions .......................................................... 11
V-A. Conducting a Test ............................................................... 11
V-B. Metering Line Trends Screen .............................................. 11
V-C. Shutdown ............................................................................ 12
V-D. Maintenance Mode ............................................................ 12
V-E. Diagnostics Screen .............................................................. 12
VI. Alarms and Warnings........................................................... 13
VI-A. Sensors ............................................................................... 13
VI-B. Alarms ................................................................................. 13
VI-C. Warnings ............................................................................. 14
VII. Maintenance/Troubleshooting ........................................... 15
VII-A. General Maintenance ........................................................ 15
VII-B. Each Operation .................................................................. 15
VII-C. Trouble Shooting ............................................................... 15
APPE NDI X A: PRODU CT WARRA N TY ...... 17
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Warnings and Cautions -
I-A. Safety Information Symbols
The following images indicate important safety information:
This General warning symbol points out important information that, if not followed,
could endanger personal safety and/or property.
This Explosion warning symbol points out potential explosion hazards.
This Fire warning symbol points out potential fire hazards.
This Electrical warning symbol points out potential electrical shock hazards.
Atlas | Operation and Installation Manual
I-B. Warnings
This load bank is high-powered, technical, industrial equipment operating at dangerous
voltages and temperatures. It is capable of damaging itself, property or personnel if
improperly used. It is not a consumer product.
It must be installed, connected and operated by personnel properly trained and
experienced in its use. An operator’s manual is supplied with each load bank and
available online at www. simplexdirect.com. The operator must be familiar with its
contents and have access to it during operation.
• High Voltage: Turn off and disconnect power source before opening this
equipment.
• High Temperature: Allow hardware to cool before servicing or opening this
equipment.
• Rotating Equipment: Ensure that the fans have stopped before opening this
unit.
• For Operator Safety: Make sure this equipment is properly grounded when
in use.
All compression-type connections on fuse blocks, load blocks, and contactors should be
checked for tightness frequently. This check should be established as part of routine
maintenance.
The following cautions should be observed before and during operation:
• Check intake and exhaust screens as well as fan and load elements for foreign
objects.
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Atlas | Operation and Installation Manual
- Warnings and Cautions
• Position and install the load bank with consideration given to large cubic
airflow requirements, exhaust temperature, and velocity. Do not point
exhaust at any nearby surface or object that may be adversely affected by
high temperature. This includes but is not limited to painted surfaces, tar
paper and asphalt roofs, water sprinkler heads, fire alarms, and volatile
material.
• Do not use in confined spaces. The load bank may have to compete with
cooling air requirements of a nearby running engine generator set where
cooling air intake to a confined space may not be adequate for both engine
and load bank. Be especially careful not to bounce hot exhaust air off nearby
obstructions for re-circulation through the load bank.
• Verify that all control switch positions are set correctly for your intended
usage before connecting the load bank to the source to be tested.
• The load cables carry high amperage. Be constantly aware of possibility of
inductively heating adjacent ferrous objects to temperatures sufficient to
damage cable insulation.
• Always connect the safety ground cable to a proper ground. Do not rely on a
possible grounded neutral somewhere else in the system.
• Do not let the load bank run unattended for long periods of time.
• Do not store or operate in rain unless adequate protection is provided.
• Routinely inspect all components and electrical connections for tightness and
integrity.
• Repair any damaged or degraded components and wiring without delay.
• If technical assistance, service, or parts are needed, please call
800-637-8603 (24 Hours).
• All hardware covered by this manual have dangerous electrical voltages and
can cause fatal electrical shock. Avoid contact with bare wires, terminals,
connections, etc. Ensure all appropriate covers, guards, grounds, and barriers
are in place before operating the equipment. If work must be done around an
operating unit, stand on an insulated dry surface to reduce the risk of
electrocution.
• Do not handle any kind of electrical device while standing in water, while
barefoot, or while your hands or feet are wet.
• If people must stand on metal or concrete while installing, servicing, adjusting,
or repairing this equipment, place insulative mats over a dry wooden
platform. Work on the equipment only while standing on such insulative mats.
• The National Electrical Code (NEC), Article 250 requires the frame to be
connected to an approved earth ground and/or grounding rods. This
grounding will help prevent dangerous electrical shock that might be caused
by a ground fault condition or by static electricity. Never disconnect the
ground wire while the load bank is in use.
• Wire gauge sizes of electrical wiring, cables, and cord sets must be adequate
to handle the maximum electrical current (ampacity) to which they will be
subjected.
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Warnings and Cautions -
• Before installing or servicing this (and related) equipment, ensure that all
power voltage supplies are completely turned off at their source. Failure to do
so can result in hazardous and possibly fatal electrical shock.
• In case of accident caused by electric shock, immediately shut down the
source of electrical power. If this is not possible, attempt to free the victim
from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a
nonconducting implement, such as a dry rope or board, to free the victim
from the live conductor. If the victim is unconscious, apply first aid and seek
immediate medical attention.
• Never wear jewelry when working on this equipment. Jewelry can conduct
electricity resulting in electric shock or may get caught in moving components
causing injury.
• Keep a fire extinguisher near the hardware at all times. Do NOT use any
carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can
deteriorate wiring insulation. Keep the extinguisher properly charged and be
familiar with its use. If there are any questions pertaining to fire extinguishers,
please consult the local fire department.
• The illustrations in this manual are examples only and may differ from your
load bank.
• Load Bank warranty is void if incorrectly cooled.
• Main Disconnect to be provided by installer, rated 600V maximum, sized 150%
maximum of rated current.
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Capacity
1000KW at 240/480V
750KW at 208/416V
630KW at 380V
667KW at 240V, 1-ph
Power Factor
1.0
Full Load Amps
2404 at 240V
1202 at 480V
Load Type
Resistive
Cooling System
Airflow: 27,700 CFM
Motor: 10 HP
Voltages
240/480V, 3-ph.
Frequency
50, 60Hz standard
Connection
3-wire plus ground
Time Rating
Continuous
Ambient Air
Temperature
120°F
Fault Rating
Fuses are rated 200KAIC. The load bank has a 5KAIC short
circuit current rating.
Fan/Control Power
Provided by either internal transformer or 230/460V, 3-ph,
60Hz external power
- Description and Specification
II-A. Specifications
Atlas | Operation and Installation Manual
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If any problems are observed
call Simplex 24 hours a day at
800-637-8603
Unpacking -
III-A. Included Components and Parts
The following items are included with your load bank. If any of the following are not included, please
contact Simplex Direct, Inc., at 800-637-8603.
1. Load bank
2. Manual
3. Human-Machine Interface (HMI)
4. Electrical drawings package
III-B. Primary Inspection
Preventative visual inspection of the shipping crate and the load bank is advised. Physical or electrical
problems due to handling and vibration may occur. Never apply power to a load bank before
performing this procedure. The following five-point inspection is recommended before installation
and as part of a 6-month maintenance schedule or as a load bank is relocated:
1. If the crate shows any signs of damage, examine the load bank in the corresponding
areas for signs of initial problems.
2. Check the entire outside of the cabinet for any visual damage, which could cause
internal electrical or mechanical problems due to reduced clearance.
3. Inspect all relays and control modules. Make sure all components are secure in their
bases and safety bails are in place. Spot check electrical connections for tightness. If any
loose connections are found, inspect and tighten all remaining connections.
4. Examine all accessible
internal electrical components
such as fuses, contactors, and
relays. Check lugged wires at
these components.
5. Visually inspect the element
chamber for foreign objects,
broken ceramic insulators,
and mechanical damage.
during primary inspection,
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Improperly installing this unit may result in
the unit.
- Installation
IV-A. Load Bank Placement
Normally equipped, Atlas-Megawatt load banks are
intended for outdoor installation. A forced air system,
which discharges out of the top of the unit, cools the load
elements (pictured right). Load banks require large
quantities of air circulation, so it is essential to install the
unit in an area that provides adequate airflow. Before
conducting load tests, a review of site conditions by
trained personnel is recommended.
The load bank requires at least 6 feet of clearance on all
sides. Because of the high exhaust temperature, do not
install anything above the load bank or install the load
bank under existing installations or in environments where
objects such as tree branches would be above the unit.
Atlas | Operation and Installation Manual
The load bank should be placed in a secure area accessible
by trained personnel only.
Because the unit generates a lot of heat, never operate
near sprinkler systems.
Operating the load bank in a confined space will recycle
hot exhaust air through the cooling system, which can cause severe damage. The load bank may
compete with nearby generators for cooling air.
damage or destruction of the load bank,
adjacent equipment, and the building housing
IV-B. Wiring the Load Bank
1. Confirm the test source is properly grounded and ground the load bank to its own independent
ground.
2. Verify the Fan Circuit Breaker (FCB) is in the “Off ” position.
3. If you will be connecting multiple load banks, use customer-supplied CAT-5, CAT-5E or CAT-6
ethernet cables to create a network by connecting the output of the master load bank to the input
of the first slave load bank. Connect as many load banks as desired by daisy-chaining load banks in
the same manner.
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Installation -
4. If you will be using the test source to provide control and fan power, plug the Fan/Control Power
Plug into the receptacle in the cable-storage area in the back of the load bank. If you will be using
external power, plug the Control Power Plug into a 230/460V, 3-phase, 60Hz, 20A receptacle.
5. Using a CAT-5, CAT-5E or CAT-6 ethernet cable, connect the HMI to the main load bank. If other
load banks are connected in Step 3, controllers can be connected to them, but they will only
provide monitoring for the unit they are connected to.
6. Using the supplied control power cord, connect the HMI controller to the load bank’s receptacle
in the controller mounting area or a 120V, 1-phase, 60Hz outlet.
7. Using the cables provided, connect the load bank to the testing source.
8. Turn the Fan Circuit Breaker on.
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- Operating Instructions
V-A. Conducting a Test
1. If you wish to enable data logging, insert a USB thumb
drive into the port underneath the HMI screen.
2. Start up the generator set or otherwise bring the test
source on line.
3. Press the “Control Power” to switch it to the “On”
position on the Main Screen (pictured above). If multiple
units are networked, the Main Screen is only available via
the Master Load Bank. Slave units will only display the
single-unit monitoring screen (pictured middle).
Atlas | Operation and Installation Manual
4. Make sure the fan is spinning, check the air intake for
obstructions, confirm air flow and investigate any unusual
noise.
5. Make sure no errors are registered in the “System” area
in the bottom left of the screen. If any errors are indicated,
consult the troubleshooting table on page 16 for
information on to resolve them.
6. Adjust the voltage and frequency of the generator.
7. Press the “KW to Apply” button and enter the desired
load (pictured bottom).
8. Press the “Apply” button.
9. Monitor and adjust load steps as needed.
V-B. Metering Line Trends Screen
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While the load bank is operating, pressing the Metering Line
Trends button in the bottom right corner of the screen will
bring up the Metering Line Trends screen (pictured left). This
screen provides a graph displaying voltage, current,
frequency, and kilowatts detected by the load bank.
If you want to record this data, insert a USB drive into the
port below the screen and press the “Data Logging Disabled”
button. When you are done, press the button again and the
load bank will write the data in a tab-delimited format to the
thumb drive.
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Operating Instructions -
If you have networked multiple load banks together, you can monitor just the master load bank by
pressing the “Load Bank Monitoring” button. This will bring up the single-unit monitoring screen.
V-C. Shutdown
1. Remove all load by pressing the Remove button on the main screen.
2. Allow the cooling fan to run for approximately five minutes to provide a thorough cooldown for
the entire system.
3. Press the “Control Power” button to switch it to the “Off ” position.
4. Turn off the test source.
5. Disconnect the cables and store them in the cable compartment.
6. Disconnect the controller(s) and ethernet cable(s) and store them appropriately.
V-D. Maintenance Mode
While the load bank’s control power is turned off, pressing
the “Maintenance Mode” button in the bottom right
corner of the screen will make the unit enter maintenance
mode (pictured right).
On this screen you can see the values the temperature
sensors are reading, the voltages of the three phases, and
check the operation of the unit’s load steps by activating
them individually.
Any load that you activate on the maintenance screen will
be dumped when you leave the screen.
The Factory Setup screen can be accessed from maintenance mode, but it is intended for Simplex
service representatives only and is password protected.
V-E. Diagnostics Screen
From the maintenance mode screen, you can enter the
Diagnostics screen (pictured right), which displays the
status of the load bank’s programmable logic controller.
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Unresolved cooling issues may result
in damage to the load bank.
- Alarms and Warnings
VI-A. Sensors
Atlas-Megawatt load banks are protected by four types of sensors.
1. Intake temperature, which checks the incoming air to ensure the load elements can
be adequately cooled.
2. Exhaust temperature, which checks the temperature of the air coming out the load
bank to ensure the load elements are being adequately cooled.
3. Fan pressure, when ensures the fan blades are forcing air into the load element
chamber.
4. Fan current, which ensures the fan motor isn’t overloaded or jammed.
VI-B. Alarms
If the load bank registers an alarm, the green “Normal Operation”
indicator on the main screen will change to a red “Load Bank
Failure” notification and the unit will dump the load. Details
about the alarm can be found on the Maintenance screen,
accessible by pressing the “Maintenance Mode” button.
The load bank’s HMI can alert you to four alarms:
• Load Bank Failure: Indicates that there is a problem
with the load bank that must be resolved
immediately.
• Exhaust Temp. Failure: Air leaving the load bank is
too hot.
• Fan Failure: Either the fan is not pushing cooling air
into the element chamber or the fan motor is
overloaded.
• Over Voltage: Indicates that the load bank has been
connected to a power source that produces a higher
voltage than the unit is configured for.
The load bank will alert you to alarms by turning the status areas for the alarm on the home screen
from green to red.
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Alarms and Warnings -
VI-C. Warnings
The load bank features one warning: Intake Temp Failure. This warning will not disable the unit and
dump the load as with the alarms, but the issue should be investigated and resolved as soon as
possible.
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Remove all power before servicing the
load bank. Never operate or service a
load bank that is not grounded.
- Maintenance/Troubleshooting
VII-A. General Maintenance
The load bank has been designed to require minimum maintenance. All components have been
chosen for a long, reliable life. Two basic intervals of maintenance are required: each operation and
either every 50 hours of use or 6 months, whichever comes first.
VII-B. Each Operation
The air intake screens and louvers, fan and cooling chamber, and exhaust openings must be
checked for any obstructions or foreign objects. Due to the high volume of air circulated, paper and
other debris can be drawn into the air intake.
During load bank operation, ensure that air is exiting from the exhaust vent.
The load branches should be checked for blown fuses or opened load resistors. To check the fuses
or load resistors, operate the load bank from a balanced 3-phase source and check the three line
currents on the metering screen. The three current readings should be essentially the same. If a
sizable difference is noted, one or more load fuses or load resistors may have malfunctioned.
VII-C. Trouble Shooting
Any of the alarms detailed on page 13 will result in the load bank entering a failure state and dumping
the load. All load steps are locked out until the problem is corrected. Until the failure is investigated
and corrected, the load cannot be reapplied. For possible solutions to the problems causing the
alarms, please consult “VII-D. Troubleshooting” on page 16. If the load bank still won’t operate,
please call the Simplex service department at 800-637-8603 ext. 4.
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VII-D. Trouble Shooting
Error
Problem
Solution
Intake
Temp.
Failure
Intake screen blocked by debris
Ambient temperature too high
Clear intake screen, located
on bottom of unit.
Move load bank to cooler
location or wait to conduct
test on cooler day, if possible.
Exhausts
Temp.
Failure
Fan has stopped running
Exhaust space insufficient
The unit needs to be
serviced. Please call the
Simplex service department
at 800-637-8603 ext. 4.
Move the unit to an area that
allows for proper air
circulation. See “Load Bank
Placement” on page 8 for
more information.
Fan failure
Fan not blowing air into element
chamber
Fan blades not turning
Clear intake screen, located
on bottom of unit.
Make sure nothing has
jammed the fan blades.
Over
Voltage
Load bank connected to too-high
voltage source
Connect load bank to
appropriate voltage source.
Maintenance/Troubleshooting -
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APPENDIX A – PRODUCT WARRANTY
SIMPLEX, Inc., warrants the industrial electrical control, test and accessory equipment
and parts and accessories thereof to be the kind and quality described in SIMPLEX’s
specifications and to be free from defects in material or workmanship under normal
service, its obligations under this warranty being limited to repairing or replacing, at its
option, any part or parts which shall, within twelve (12) months from date of shipment
from its factory, as indicated by serial date code on the nameplate or sales records, be
returned to SIMPLEX or an authorized SIMPLEX repair station, with transportation costs
prepaid, and which its examination shall disclose to its satisfaction to have been thus
defective.
The provisions of this warranty shall not apply to any equipment, part or accessory which
(a) has been improperly specified by buyer;
(b) has been improperly stored or handled prior to placing in service;
(c) has been improperly mounted or connected;
(d) has not been operated within specifications stated on its nameplate, label or placard;
(e) has not been properly maintained;
(f) parts supplied by buyer for inclusion in finished equipment are not covered by this
warranty;
(g) components or assemblies specified by buyer with no substitution permissible that are
not normally used by SIMPLEX.
SIMPLEX reserves the right to reject warranty claims of any kind against assembled
equipment, parts or material for which SIMPLEX has not received payment in full.
Should buyer, at his own risk, elect to replace defective equipment or parts in the field
rather than return equipment to SIMPLEX’s factory or authorized repair station, SIMPLEX
will supply and invoice parts at normal prices upon receipt of buyer’s bona-fide purchase
order. Defective equipment or parts returned for in-warranty crediting in exchange for
replacement parts must be returned within 45 days from date of shipment of
replacement in order to qualify for warranty consideration. Defective equipment or parts
returned after 45 days may be subject to a restocking charge of 20% or a minimum charge
of $50.00, whichever is greater.
This warranty is in lieu of all other warranties, express or implied, and all other
obligations or liabilities on the part of SIMPLEX, and SIMPLEX neither assumes nor
authorizes any other person to assume for it any other liability in connection with any
such electrical control, test or accessory equipment or accessories or parts.
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for all your Load Bank and Fuel Supply needs.
Simplex, Inc.
5300 Rising Moon Road
Springfield, IL 62711
800-637-8603
www.simplexdirect.com
This manual and all of its contents Copyright
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© 2019 Simplex, Inc. All Rights Reserved
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